Method of making personal computer cards

ABSTRACT

An enclosure for a personal computer card is constructed by folding a single sheet of material into confronting upper and lower enclosure members which are then secured together in the confronting arrangement by nested side walls and channels formed along peripheral edges of the enclosure members to house an electronic device within the enclosure.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a division of application Ser. No. 08/106,210, filedAug. 13, 1993, now U.S. Pat. No. 5,386,340.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to personal computer cards andpertains, more specifically, to a method for making personal computercards in which an electronic device is housed within an enclosure forconvenient interconnection with a personal computer.

The increasing popularity of small portable computers, such as notebooksand hand-held computer systems, has given rise to the requirement forsmaller, more compact devices, such as electronic memory devices,capable of use in connection with these computers. Personal computercards, known as PC Cards, have been developed for adding memory, storageand input/output capabilities to such small portable computer systems.PC Cards are about the size and shape of a standard credit card andprovide a wide variety of increased capabilities to host apparatus, suchas laptops, notebooks, palmtops, tablets and other portable computingsystems, equipped with a slot for receiving a PC Card.

2. Description of the Prior Art

The overall structure of a PC Card includes an enclosure within whichthere is housed an electronic device, which device usually includeselectronic components mounted upon a circuit board, a power source, suchas a battery, and connectors for enabling interconnection with aportable computing system, as well as for providing input/outputcapabilities. The enclosure usually is constructed of steel, preferablystainless steel, for strength and rigidity, so as to maintain thestructural integrity and dimensional stability required in a PC Card, aswell as for providing an effective electrically conductive shieldingenvelope for the electronic device housed within the enclosure.

SUMMARY OF THE INVENTION

The present invention provides an improvement in a method for makingpersonal computer cards, and attains several objects and advantages,some of which are summarized as follows: Enables the economicalmanufacture of effectively enclosed personal computer cards; provides PCCard enclosures of accurate dimensions, and requisite strength andrigidity to maintain structural integrity and dimensional stabilitythroughout an extended service life; simplifies the assembly andcompletion of PC Cards; provides added flexibility in the design andconstruction of PC Cards for enhanced information storage and processingcapabilities; accommodates a wide variety of PC Card configurationswhile providing enhanced strength, rigidity and electrical shieldingintegrity; facilitates high speed production and assembly techniques forthe economical manufacture of PC Cards in large numbers of consistenthigh quality.

The above objects and advantages, as well as further objects andadvantages, are attained by the present invention, which may bedescribed briefly as an improvement in a method for making a personalcomputer card in which an electronic device is housed within anenclosure for convenient interconnection with a personal computer, thepersonal computer card having a generally rectangular plan configurationincluding longitudinal sides and lateral ends, and a predeterminedthickness, the improvement comprising the steps of: forming first andsecond enclosure members, with each enclosure member having a generallyrectangular plan configuration and including a panel, longitudinal sideedges corresponding to the longitudinal sides of the personal computercard, and lateral end edges corresponding to the lateral ends of thepersonal computer card; forming side walls integral with the panel of atleast the first enclosure member and extending longitudinally along thelongitudinal side edges of the first enclosure member, the side wallshaving a side wall width extending altitudinally; forming channelsintegral with the panel of at least the second enclosure member andextending longitudinally along the longitudinal side edges of the secondenclosure member, the channels having an external channel widthextending altitudinally and corresponding to the thickness of thepersonal computer card, and an internal channel width; and juxtaposingthe first and second enclosure members in opposed arrangement with thepanels confronting one another and with the side walls of the firstenclosure member nested within corresponding channels of the secondenclosure member to secure the first and second enclosure memberstogether with the respective panels opposed to one another and spacedapart to accommodate the electronic device between the opposed panels.

BRIEF DESCRIPTION OF THE DRAWING

The invention will be understood more fully, while still further objectsand advantages will become apparent, in the following detaileddescription of preferred embodiments of the invention illustrated in theaccompanying drawing, in which:

FIG. 1 is a perspective view of a personal computer card constructed inaccordance with the present invention, with portions cut away forillustrative purposes;

FIG. 2 is a plan view of a blank for the enclosure of the personalcomputer card;

FIG. 3 is a plan view of the personal computer card, with portions shownin phantom to illustrate steps in the improved method of the presentinvention;

FIG. 4 is an enlarged fragmentary cross-sectional view taken along line4--4 of FIG. 3;

FIG. 5 is an enlarged fragmentary cross-sectional view taken along line5--5 of FIG. 3; and

FIG. 6 is an enlarged fragmentary cross-sectional view similar to FIG.4, and showing an alternate construction.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawing, and especially to FIG. 1 thereof, apersonal computer card is shown in the form of PC Card 10 constructed inaccordance with the present invention and including an enclosure 12housing an electronic device 14 having a circuit board 20 upon which ismounted a plurality of electronic components 22, in a manner now wellknown in the construction of electronic devices, a power source in theform of a battery 24, and a connector 26. Enclosure 12 houses theelectronic device 14, including the circuit board 20, the battery 24 andthe connector 26, and provides a relatively high strength, rigid housingfor the PC Card 10, while at the same time serving as an electricallyconductive shielding envelope necessary for the proper operation of thePC Card 10. PC Card 10 has a generally rectangular plan configurationwith a periphery including longitudinal sides 30 of prescribed lengthand lateral ends 32 and 34 of given width, and has a predeterminedthickness T along the longitudinal sides 30 and the lateral ends 32 and34.

Turning now to FIG. 2, enclosure 12 is constructed from a blank 40stamped from a sheet of metal, preferably stainless steel, in a unitary,one-piece construction. Blank 40 includes first and second enclosuremembers 42 and 44 joined together by bridges 46 which define an opening48 between the first enclosure member 42 and the second enclosure member44. First enclosure member 42 has a generally rectangular planconfiguration and includes a panel 50 having a periphery which includeslongitudinal side edges 52, corresponding to the longitudinal sides 30of the PC Card 10, and lateral end edges 54 and 56 correspondingrespectively to the lateral ends 32 and 34 of the PC Card 10. Likewise,second enclosure member 44 has a generally rectangular planconfiguration and includes a panel 60 having a periphery which includeslongitudinal side edges 62, corresponding to the longitudinal sides 30of the PC Card 10, and lateral end edges 64 and 66, correspondingrespectively to the lateral ends 32 and 34 of the PC Card 10. Side walltabs 70 are unitary with panel 50 along longitudinal side edges 52, andside wall tabs 72 are unitary with panel 60 along longitudinal sideedges 62. In a similar manner, end wall tabs 74 are unitary with panel50 along lateral end edge 56, and end wall tabs 76 are unitary withpanel 60 along lateral end edge 66, for purposes which will be set forthin detail below.

In one preferred embodiment of the construction of PC Card 10, the sidewall tabs 70 are formed, as by bending, as indicated in phantom in FIGS.3 and 4, preferably into a channel 80, and the electronic device 14 isplaced upon the first enclosure member 42 and located between theopposite channels 80. Each channel 80 includes a side wall 82 having analtitudinally extending side wall width, shown in the form of externalchannel width 83, and a flange 84 placed along a corresponding portionof a frame 86 within which the circuit board 20 is seated to capture theframe 86 and circuit board 20 and hold the electronic device 14 in placewithin a shell-like configuration established in the first enclosuremember 42. In a similar manner, end wall tabs 74 of the first enclosuremember 42 are formed into channels 88, as indicated in phantom in FIGS.3 and 5, which channels 88 are placed along a corresponding portion offrame 86. Side wall tabs 72 of the second enclosure member 44 are formedinto channels 90, as indicated in phantom in FIGS. 3 and 4, whichchannels 90 include a side wall 94 and a flange 96. Channels 90 have aninternal channel width 98 complementary to the external channel width 83of each corresponding channel 80 so that the relative dimensions, inparticular, the altitudinal distance over which external channel width83 extends and the altitudinal distance over which internal channelwidth 98 extends, and the relative locations of the channels 80 and 90assure that channels 80 are nested and secured within correspondingchannels 90. Further, channels 90 have an external channel widthcorresponding to the thickness T of PC Card 10. In a similar manner, endwall tabs 76 are formed into channels 100 having side walls 102 andflanges 104, within which channels 100 are nested corresponding channels88. Thus, the shell-like configuration established in the secondenclosure member 44 is secured to the shell-like configuration of thefirst enclosure member 42 and the electronic device 14 is envelopedwithin enclosure 12 between the first and second enclosure members 42and 44. It is noted that channels 80 and 88 each are offset from thepanel 50 of the first enclosure member 42 at 106 and at 108,respectively, so that the flanges 96 and 104 are seated within therespective offsets 106 and 108 to accommodate flanges 96 and 104 withinthe overall thickness between the opposed panels 50 and 60 of juxtaposedfirst and second enclosure members 42 and 44.

First and second enclosure members 42 and 44 are juxtaposed with oneanother, as seen in FIG. 3, by folding blank 40 so that the first andsecond enclosure members 42 and 44 become lower and upper shell-likemembers, respectively, of enclosure 12. Such folding is accomplishedabout fold lines 109 which define the length of the bridges 46 and,hence, the thickness T of the PC Card 10 at the lateral end 32. Theopening 48 between the bridges 46 establishes the necessary access tothe connector 26 of the electronic device 14 so that upon insertion ofthe inner end 32 of the PC Card 10 into the appropriate slot in a hostapparatus, such as a personal computer or the like, the PC Card 10 isconnected to the host device for proper operation. The tabs 74 and 76 atthe respective lateral end edges 56 and 66 of the first and secondmembers 42 and 44 are arranged along the lateral end edges 56 and 66 soas to provide spaces 110 and 112 at predetermined locations along therespective lateral end edges 56 and 66. These spaces 110 and 112 arelocated so as to accommodate the various configurations required for theselected input/output interconnection at the end 34 of the PC Card 10.Thus, PC Card 10 is selectively constructed to accept modem connections,network connections, printer connections, and other peripherals, as wellas various extensions ordinarily added to the input/output end of the PCCard 10.

Since the forming of the blank 40 is accomplished by stamping in highlyaccurate die sets, and since the formation of the channels 80 and 90likewise is accomplished in accurately dimensioned tools, the dimensionsof the PC Card enclosure 12 are held to very close tolerances, enablingthe attainment of an exceptionally high degree of accuracy with relativeease and economy. The construction which utilizes nested channels,especially along the longitudinal sides 30 of the PC Card 10, providesenhanced rigidity for resisting bending, twisting and other distortionsduring use, thereby accomplishing exemplary dimensional stability whileaffording maximum protection to the internal components of the PC Card.In addition, the nested channels 80 and 90, as well as the nestedchannels 88 and 100, provide electrical continuity for enabling a highdegree of electrical integrity in the shielding arrangement establishedby the enclosure 12. In addition, the integral metal construction ofenclosure 12, including the nested edges of the shell-like first andsecond enclosure members 42 and 44, provides for enhanced groundingconnections between the enclosure 12 and the host apparatus. Theimproved method of construction lends itself to relatively high speedproduction and assembly techniques for economical manufacture.

In the preferred method, the channels 90 and 100 are formed prior tojuxtaposition of the first and second enclosure members 42 and 44 sothat upon folding the first and second enclosure members 42 and 44 intoopposed juxtaposition with one another, the channels 90 and 100 merelyare snapped over corresponding channels 80 and 88 to complete theassembly of the PC Card 10. In an alternate method, the channels 90 and100 are formed after the first and second enclosure members 42 and 44are folded into juxtaposition with one another. The electronic device 14is placed within the first enclosure member 42 prior to juxtaposition ofthe first and second enclosure members 42 and 44 so that assembly iscomplete merely by folding the blank 40, as described. In this manner,final assembly of the PC Card 10 is accomplished without the requirementfor extensive special tools or skills, and requires no fasteners,adhesives, welding or other time-consuming or intricate joiningprocedures or systems for the completion of a reliable PC Card 10.Again, the accuracy with which the channels 80, 90, 88 and 100 areformed enables the achievement of closely controlled dimensions in thecompleted PC Card, with ease of manufacture.

Turning now to FIG. 6, another embodiment of the invention isillustrated in the form of PC Card 120 which has a thickness TT greaterthan the thickness T of the PC Card 10 described above. In the presentembodiment, channel 122 along the panel 124 of the lower enclosuremember 126 has an external channel width 130 which is less than theinternal channel width 132 of channel 134 along the panel 136 of theupper enclosure member 138. Either a frame 140, as shown, or the circuitboard 20 of electronic device 14, is captured between the flange 142 ofthe channel 122 and the panel 136 of the upper enclosure member 138. Asin the embodiment described in connection with FIGS. 1 through 5,channel 122 is nested within channel 134 to complete and secure theassembly.

It will be seen that the present invention attains the objects andadvantages summarized above, namely: Enables the economical manufactureof effectively enclosed personal computer cards; provides PC Cardenclosures of accurate dimensions, and requisite strength and rigidityto maintain structural integrity and dimensional stability throughout anextended service life; simplifies the assembly and completion of PCCards; provides added flexibility in the design and construction of PCCards for enhanced information storage and processing capabilities;accommodates a wide variety of PC Card configurations while providingenhanced strength, rigidity and electrical shielding integrity;facilitates high speed production and assembly techniques for theeconomical manufacture of PC Cards in large numbers of consistent highquality.

It is to be understood that the above detailed description of preferredembodiments of the invention is provided by way of description only.Various details of design, construction and procedure may be modifiedwithout departing from the true spirit and scope of the invention, asset forth in the appended claims.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:
 1. An improvement in amethod for making a personal computer card in which an electronic deviceis housed within an enclosure for convenient interconnection with a hostdevice, the personal computer card having a generally rectangular planconfiguration including longitudinal sides and lateral ends, and apredetermined thickness along the longitudinal sides and lateral ends ofthe personal computer card, and the enclosure having longitudinal sidesand lateral ends corresponding to the longitudinal sides and lateralends of the personal computer card, and a thickness along thelongitudinal sides and lateral ends of the enclosure equal to thecorresponding predetermined thickness of the personal computer card, theimprovement comprising the steps of:forming first and second enclosuremembers, with each enclosure member having a generally rectangular planconfiguration and including a panel, longitudinal side edgescorresponding to the longitudinal sides of the enclosure, and lateralend edges corresponding to the lateral ends of the enclosure; formingside walls integral with the panel of at least the first enclosuremember and extending longitudinally along the longitudinal side edges ofthe first enclosure member, the side walls having a side wall widthextending altitudinally a predetermined distance; forming channelsintegral with the panel of at least the second enclosure member andextending longitudinally along the longitudinal side edges of the secondenclosure member, the channels having an external channel widthextending altitudinally a first distance equal to the thickness of theenclosure along the longitudinal sides of the enclosure, and thechannels each having an internal channel width; and juxtaposing thefirst and second enclosure members in opposed arrangement with thepanels confronting one another and with the side walls of the firstenclosure member nested within corresponding channels of the secondenclosure member to secure the first and second enclosure memberstogether with the respective panels opposed to one another and spacedapart altitudinally to accommodate the electronic device between theopposed panels and to maintain the thickness along the longitudinalsides of the enclosure.
 2. The invention of claim 1 wherein the step offorming the channels in the second enclosure member precedes the step ofjuxtaposing the first and second enclosure members in opposedarrangement.
 3. The invention of claim 1 wherein the step of forming thechannels in the second enclosure member is subsequent to the step ofjuxtaposing the first and second enclosure members in opposedarrangement.
 4. The invention of claim 1 including placing theelectronic device within the first enclosure member prior to juxtaposingthe first and second enclosure members in opposed arrangement.
 5. Theinvention of claim 1 wherein the first and second enclosure members areformed in a unitary sheet of material and the step of juxtaposing thefirst and second enclosure members in opposed arrangement includesfolding the unitary sheet along predetermined fold lines.
 6. Theinvention of claim 5 wherein the step of forming the channels in thesecond enclosure member precedes the step of juxtaposing the first andsecond enclosure members in opposed arrangement.
 7. The invention ofclaim 5 wherein the step of forming the channels in the second enclosuremember is subsequent to the step of juxtaposing the first and secondenclosure members in opposed arrangement.
 8. The invention of claim 5including placing the electronic device within the first enclosuremember prior to juxtaposing the first and second enclosure members inopposed arrangement.